cracked gas tank

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i just found out i have a cracked gas tank right b4 a 4 day ride in nevada does anyone know if the kdx is the same gas tank either stock or aftermarket i imagine the 200;s gas tank would be too low to clear for the top end as the 200 doesnt have all that valve stuff well any response would be great thanks i just need a gas tank

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how big is the crack,,,im sure u can repair it,,,i just fixed the tank off my klx,,,just get a soldering iron and melt the plactic,,,i also took a cap off a paint can and used it to help fill the crack,,,

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This is what I did today to get me back on the road. Mine was a used bike and someone had cut the tank with a razor blade while making custom graphics.

Well, I just got done giving the plastic welding a try.. and it worked!

I used a soldering gun with a wide tip that is used for stained glass. I removed all the gas, blew compressed air into the tank for 10 or 15 min trying to evaporate the gas. cleaned the outside of the tank and crack with brake cleaner or acetone.

With the cut being so sharp I did not have to use any filler rod. The suggestions I have is to know how thick your plastic is, and be willing to ruin it. I started off pressing the tank inward to reduce the bulge outward from the cuts. I applied the iron onto the plastic and made circular motions over the crack over lapping it by about 1/8 inch on each side in some key areas. Like tack welding sheetmetal, then I proceeded to make a light weld over the entire length of the cut not letting it get too hot. once I sealed the crack I went back over the entire thing again, but a little wider and deeper into the plastic. I would guess close to 3/4 of the thickness of the plastic. The plastic wants to push away from the iron, put while the plastic is still hot I folded it back into the weld with the iron.

The only thing I would of done different is clean the tip of the iron alot better or start with a fresh one. Even tho I cleaned the tip well it seemed to flake a little and put black specs in the weld. I would compare plastic welding to torch type welding with oxy/acetelyne, circular motions over the crack, get good penetration, and make the weld wide to get plastic material melted at least 1/8 inch wider on each side so you can fold new plastic in the crack.

Hopefully it will not be to brittle in this area and crack again, but it got me back on the road till I find a replacement.

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Wheels7 - If you're in so cal, I've got a tank you can pick up. If you're not in so cal I could probably ship it to you. It has one little issue, but is definately good to go. PM me if you're interested. Bill